Heat insulating paper cups

ABSTRACT

A heat insulating paper cup having an improved seal. The cup can include a body member having an inside surface and outside surface, and a bottom panel member having a upper surface and a bottom surface. The body member is coated (or in some instances partially coated) on its outside surface with a foamed low density polyethylene, and on its inside surface with an unfoamed modified low density polyethylene. The bottom panel member is coated on its upper surface with or an unfoamed low density polyethylene or foamed or unfoamed modified low polyethylene. The body member and bottom panel are oriented and joined to form a heat seal at an interface between a portion of the unfoamed modified low density polyethylene coated on the inside surface of the body member and a portion of unfoamed low density polyethylene or unfoamed modified low density polyethylene coated on the upper surface of the bottom panel member.

This is a continuation of application Ser. No. 08/870,486, filed Jun. 6,1997, now U.S. Pat. No. 6,416,829, which is incorporated herein byreference.

BACKGROUND OF THE INVENTION

This invention relates to heat-insulating paper containers, and moreparticularly to heat-insulating paper cups used for coffee and other hotor cold beverages.

Several types of heat-insulating cups have been used commercially forhot and cold liquids. Examples include the wide variety of existingpolystyrene foam cups. These cups are typically made by adding a foamingagent to a polystyrene resin, casting the mixture into a mold, heatingthe resin under pressure to foam it, and removing the shaped articlefrom the mold. Such cups have outstanding heat-insulating properties,but require a lot of energy to make, and are costly to dispose of in anenvironmentally acceptable way.

A variety of paper-based cups have been proposed as environmentallyacceptable alternatives to polystyrene containers. Unfortunately, mostattempts to produce paper-based heat-insulating cups have proved costlydue to the complexity of their manufacturing processes. One example is acup where the side wall is surrounded by a corrugated heat-insulatingjacket. Its process for manufacture involves additional steps of formingthe corrugated paper jacket and bonding it to the outer surface of theside wall of the cup. These cups, however, have proved to beaesthetically unappealing and structurally deficient. In this regard,only the ridges of the corrugated jacket contact the body of the papercup in such a way that the bond between the two is so weak that the cupand jacket easily separate. Also such cups are not easily nested makingstorage difficult.

Another type of insulating paper cup is that where the cup has a dualcup structure. An inner cup is given a different taper than an outer cupto form a heat-insulting air layer in between the two cups. The two cupsare integrated by curling their respective upper edges into a brim. Thedual structure adds to manufacturing costs, and the two cups of thestructure are prone to separation.

One of the most widely accepted types of heat-insulating paper-basedcups include those described in U.S. Pat. No. 4,435,344, and alsoreferred to in U.S. Pat. No. 5,490,631. Those cups have good insultingproperties and can be prepared at a relatively low cost. Such cups arefabricated from a body member and a bottom member, both cut from a papersheet.

For the cups described in the aforementioned U.S. patents, one surfaceof the body member is coated or laminated with a thermoplastic syntheticresin film, and the other surface of the body member is coated orlaminated with the same or different thermoplastic synthetic resin filmor an aluminum foil, to thereby foam the thermoplastic synthetic resinfilm and form a heat-insulting layer on at least one surface of thecontainer, i.e., the outer surface. Water present in the paper isvaporized upon heating during processing, causing the thermoplasticresin film on the outer surface to foam.

Commercial versions of cups prepared according to U.S. Pat. No.4,435,344 include a body member and a bottom panel member. The bodymember comprises a paper sheet coated or laminated on one side with afoamed heat-insulating layer of low density polyethylene which entirelycovers its outer surface. The inner surface of the body member iscovered by with an unfoamed film of high density polyethylene. Thebottom panel member is laminated on its inner or upper surface with lowdensity polyethylene film. The inside surface of the body member, andthe inside surface of the bottom member are coated to preventpenetration of liquid contents into the paper sheet during use. Theinside surface of the body member is also coated to ensure that thewater in the paper will not evaporate directly into the air atmosphereduring heating of the fabricated cup.

For these commercial cups, the film to be laminated on the inner surfaceof the body member is high density polyethylene because it has a highersoftening point than the low density polyethylene film on the outersurface. Upon heating during fabrication, the moisture inherentlypresent in paper sheet serves as the foaming agent for the outer surfacelayer of low density polyethylene film. The high density polyethylene onthe inside surface of the body member will not foam under fabricationconditions but serves to seal the interior of the cup thus preventing anescape of the moisture necessary to foam the low density polyethylene onthe outer surface of the cup.

A significant drawback of the aforementioned cups is that they aredifficult to adequately seal when fabricated under desirable commercialconditions, i.e., high cup-forming machine speeds. When assembling suchcups using conventional cup-forming machines, the bottom panel memberand the body member are oriented in such a way that upon folding,heating and sealing the body member inner layer of high densitypolyethylene and the unfoamed polyethylene inner layer of the bottompanel member are in contact. Applicants have found that when fabricatedunder high cup-forming machine speeds leaking occurs at this juncturebetween inner layer of high density polyethylene of the body member, andthe unfoamed polyethylene inner layer of the bottom panel member.

One object of the invention, therefore, was to develop a heat-insulatingpaper cup which does not leak when fabricated under high cup-formingmachine speeds. While numerous exotic solutions could be envisionedinvolving a redesign of the cup structure and/or cup-forming machines,it was a further object of the invention to develop such a cup whichcould be fabricated still using conventional and existing cup-formingmachines. In this regard, it was also an object of the invention toaddress the leaking problem while maintaining as many of theconventional operating conditions and materials as possible therebyavoiding extensive redesigns of existing mass production operations forcommercial cups.

SUMMARY OF THE INVENTION

Applicants have surprisingly found improved seals for the bottoms ofheat insulating paper cups at the seam where the body member and bottompanel member are joined during fabrication. These seals include aportion of the bottom panel member paper sheet laminated with lowdensity polyethylene oriented in such a manner to contact the innerlayer of the body member coated with a modified low densitypolyethylene. Upon the application of heat and pressure duringfabrication, the two different laminated low density polyethylenesinteract to form an effective bonding layer at the interface between thetwo members.

Accordingly, the invention is directed to a heat insulating paper cuphaving an improved seal. In an additional embodiment, the cup includes abody member having an inside surface and an outside surface, and abottom panel member having a upper surface and a bottom surface. Thebody member is coated (or in some instances partially coated) on itsoutside surface with a foamed low density polyethylene, and on itsinside surface with an unfoamed modified low density polyethylene. Thebottom panel member is coated on its upper surface with an unfoamed lowdensity polyethylene or unfoamed modified low density polyethylene. Thebody member and bottom panel member are oriented and joined to form aheat seal at an interface between a portion of the unfoamed modified lowdensity polyethylene coated on the inside surface of the body member anda portion of unfoamed low density polyethylene or unfoamed modified lowdensity polyethylene coated on the upper surface of the bottom panelmember. The modified low density polyethylene is a low densitypolyethylene modified in a manner effective to provide an improved sealbetween the bottom panel member and the body member of a cup whenfabricated at a speed of at least 165 cups per minute for a 12 ounce cupby a HORAUF MODEL BMP-200 machine, made by Michael HoraufMaschinenfabrik GMBH AND Co KG, with temperature controls set at betweenabout 350° to about 460° C. and a bottom expansion pressure set at about3000 kilopascals for two revolutions per cup.

An improved seal is a relative characteristic, and for purposes of thisinvention it is intended to be relative to seals in cups made in thesame way except using an inside surface of the body member coated with100% high density polyethylene. When mass producing cups according tothe present invention an improved seal can be obtained usingconventional cup-forming machines. When making 12 ounce cups using theHORAUF MODEL BMP-200 (with temperature controls set at between about350° to about 460° C. and a bottom expansion pressure set at about 3000kilopascals for two revolutions per cup), for example, sealing can beobtained at higher than normal fabrication speeds such as more thanabout 165 cups per minute, preferably even about 200 cups/minute ormore, which is at least comparable to that obtained with 100% highdensity cups made at slower, more conventional speeds such as about 165cups per minute or less. For 12 ounce cups according to the presentinvention fabricated using the HORAUF MODEL BMP-200 (with temperaturecontrols set at between about 350° to about 460° C. and a bottomexpansion pressure set at about 3000 kilopascals for two revolutions percup), at slower speeds such as about 165 cups per minute or less, therecan be a reduction in the number of leaking cups.

The modified low density polyethylene may be a polyethylene blendcontaining low density polyethylene in an amount effective to provide animproved seal between the bottom panel member and the body member of acup, and an amount of high density polyethylene or other polyethylenesuch that the modified low density polyethylene(s) will not foam underconditions of about 240° F. to about 270° F. and a residence time ofabout 1.5 to about 2.5 minutes, when the cup is subjected to the foamingoperation in a forced hot-air oven.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a simplified cross-section of an example of a heat-insulatingpaper cup according to the invention.

FIG. 2 is an enlarged section of the seal region between the body memberand bottom panel member of the cup of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The invention provides a heat-insulating paper cup fabricated from abody member of paper having an inside surface laminate of a polyethylenecomponent effective to prevent penetration of liquid into the paperduring use and an outside surface laminate of heat insulating foamed lowdensity polyethylene, said body member bonded to a bottom panel memberhaving a upper surface and a bottom surface, wherein the joined portionsof the said bottom panel member and body member form an improved seal ina cup when fabricated at a speed of at least 165 cups per minute for a12 ounce cup by a HORALF MODEL BMP-200 machine, made by Michael HoraufMaschinenfabrik GMBH AND Co KG, with temperature controls set at betweenabout 350° to about 460° C. and a bottom expansion pressure set at about3000 kilopascals for two revolutions per cup.

As noted above, FIG. 1 is a simplified cross-section of an example of aheat-insulating paper cup according to the invention. The cup generallyindicated by 1 includes a body member 3 and a bottom panel member 6. Thebody member 3 comprises a paper sheet 2 laminated on one side with aheat-insulating layer 4 of low density polyethylene which entirelycovers its outer surface. The inner surface of the body member iscovered with an unfoamed film 5 of modified low density polyethylene.This inner lining 5 of body member 3 provides a seal to prevent thepenetration of liquid contents into the paper during use, and, of equalimportance, ensures that the water in the paper will not evaporatedirectly into the air atmosphere when the cup is heated during thefoaming operation. If the inside of body member 3 has not been sealed byan inner laminate, water will evaporate through the inside of the cupupon heating, resulting in a foaming failure of the outer surfacepolyethylene film. It is the moisture inherently present in paper sheet2 which serves as the foaming agent for the outer surface layer ofpolyethylene film.

The inner or upper surface of the bottom panel member 6 preferably willbe also laminated with a low density polyethylene film 7, although itmay also be laminated with a modified low density polyethylene film likethe inner surface of the body member. This serves to prevent penetrationof the liquid contents of the cup into the paper sheet 8 during use.Preferably, only the inside surface of the bottom panel member 6 islaminated, when it is not important to prevent evaporation of moisturefrom paper sheet 8 of the bottom panel member 6 during the foamingoperation. In fact it is desirable to allow evaporation of moisture frompaper sheet 8 when it is not desired to foam the inside of bottom panelmember 6. Just like the low density polyethylene film on the outersurface of body member 3, he low density film on the inside of bottompanel member 6 could foam if sufficient moisture was blocked by abacking layer on the outside of the bottom panel member 6.

As noted above, one object of the present invention was to provide aheat-insulating paper cup with improved sealing properties, which couldnevertheless be prepared using mostly cost effective materials andmachinery. In this regard, low density polyethylene is less expensivethan high density polyethylene. Thus, using a modified low densitypolyethylene containing a predominate proportion of low densitypolyethylene (rather than 100% high density polyethylene) on the insidesurface of the body member is an attractive alternative from an economicstandpoint.

The heat-insulating cup can be fabricated by means of conventionalcup-forming machines, such as the HORAUF MODEL BMP-200 machine, made byMichael Horauf Maschinenfabrik GMBH AND Co KG. First, the outer surfaceof a paper sheet for the body member can be extrusion-laminated with afilm of low density polyethylene. The inner surface of the paper sheetis laminated with a modified low density polyethylene. A paper sheet formaking the bottom panel member is also laminated with a low densitypolyethylene (or a modified low density polyethylene), on one side. Ablank is cut from each of the paper sheets. Using a conventional HORAUFcup-forming machine, the two blanks are fabricated into a container,with the blank for the bottom panel member oriented in such a way thatthe film laminated side faces upward. The bottom panel member and bodymember are joined and heat sealed by applying heat and pressure to formthe bottom ridge of the cup. Pressure is applied by an expansion rolleron the inner bottom rim of the cup. It is preferred that the expansionroller be adjusted to make two revolutions per cup. These cups can befabricated on automated HORAUF machines at speeds of about 165 cups perminute or more, preferably at least about 180 cups per minute, and morepreferably about 200 cups per minute or more, for 12 ounce cups.

A thus-fabricated cup is then subjected to a heat treatment in order tocause moisture in the paper to vaporize, soften the low densitypolyethylene, and foam the outer surface of the body member. The cupscan be heat-treated by being conveyed through an oven. The conveyance ofthe cups through the oven can be performed by laying the cups en masseusually onto a metal conveyor belt, the cups being in an inverted state,i.e., supported on their rims.

The thicknesses of the films to be laminated on the body member andbottom panel members of cups according to the invention are not limitedto any particular values. However, the thickness of the low densitypolyethylene on the outer surface of the body member should be ofsufficient thickness to provide a desired thickness of heat insultingfoam. Suitable thicknesses for such films can be from 25 to 60 μm. Thethickness of the films to be laminated on the inner surfaces of the bodymember and the bottom panel member need only be so thick as to besufficient to ensure resistance to liquid permeation during use.

The paper sheet used to prepare cups according to the invention can bethose conventionally used to prepare cups of this type. They preferablyhave basis weights in the range of 100 g/m² to 400 g/m². It is alsopreferable that the paper sheets have a water content of from about 3%to about 10%.

The heating time and temperature for the foaming operation can also bethose conventionally used. For example, the temperature can vary fromabout 240° F. to about 270° F., and the heating time can vary from about1.5 minutes to about 2.5 minutes.

Any conventional heating means such as hot air, electric heat ormicrowaves can be used. Heating by hot air or electric heat in a tunnelhaving transporting means such as a conveyor has the advantage ofaccomplishing mass production at low cost.

Coating and laminating as used herein have been and are usedinterchangeably. The low density polyethylenes used herein as coatingsor laminates include those polyethylenes that have highly branched andwidely spaced chains. Such branched chain polyethylenes are typicallycharacterized as having densities of about 0.910 to about 0.925 g/cm³,crystallinities of about 50-60%, and melting points (T_(peak)) in therange of about 100° C. to about 110° C. (about 212° F. to about 230°F.).

Low density polyethylenes can be prepared by conventional methods. Forexample, such polyethylenes can be prepared by polymerization in afree-radical-initiated liquid phase reaction at about 1500 atm (22,000psi) and about 375° F., with oxygen as a catalyst (usually fromperoxides). Vapor phase techniques are also used by polyethylenemanufacturers. These use pressures of only about 100 to about 300 psi atless than about 212° F.

A preferred low density polyethylene is PE 4517 sold by Chevron ChemicalCompany. PE 4517 is a low density polyethylene extrusion coating resin.It has a melt index of 5.0 gms/10 min. (ASTM test method D1238-62T), anda density of 0.923 g/cc (ASTM test method D1505-60T)

Modified low density polyethylenes include the aforementioned lowdensity polyethylenes blended with enough non-low density polyethylene,such as high density polyethylene, to prevent laminates of the modifiedlow density polyethylenes from foaming when fabricated cups aresubjected to the foaming operation. For example, enough high densitypolyethylene must be present such that a laminate of modified lowdensity polyethylene on the inside surface of the body member of afabricated cup will not foam under conditions of about 240° F. to about270° F. and a residence time of about 1.5 to about 2.5 minutes, when thecup is subjected to the foaming operation in a forced hot-air oven. Onthe other hand, enough low density polyethylene must be present in theblend such that an effective seal is obtained between the body memberand the bottom panel member. An effective seal is one which provides animproved seal between the bottom panel member and the body member of acup when fabricated at a speed of at least 165 cups per minute for a 12ounce cup by a HORAUF MODEL BMP-200 machine, made by Michael HoraufMaschinenfabrik GMBH AND Co KG, with temperature controls set at betweenabout 3500 to about 460° C. and a bottom expansion pressure set at about3000 kilopascals for two revolutions per cup.

Examples of blends suitable to meet the objectives of the inventioninclude those containing approximately 90% low density polyethylene (10%high density polyethylene), and those containing 10% low densitypolyethylene (90% high density polyethylene). Such blends have beenfound not to foam under conditions of about 240° F. to about 270° F. anda residence time of about 1.5 to about 2.5 minutes, when the cup issubjected to the foaming operation in a forced hot-air oven, yet canexhibit an improved seal in a 12 ounce cup fabricated at a speed of atleast about 165 cups per minute by a HORAUF MODEL BMP-200 machine, madeby Michael Horauf Maschinenfabrik GMBH AND Co KG, with temperaturecontrols set at between about 350° to about 460° C. and a bottomexpansion pressure set at about 3000 kilopascals for two revolutions percup.

The blends can also contain as little as about 2% to about 7% highdensity polyethylene, although about 10% high density polyethylene ispreferred.

High density polyethylenes as used herein include those that havecomparatively straight or linear chains which are closely aligned. Thephysical properties are much different from those of low densitypolyethylenes because of the increased density. Such linearpolyethylenes are typically characterized as having densities in therange of about 0.941 to about 0.965 g/cm³, crystallinities typicallycharacterized in the range of about 90%, and melting points (T_(peak))in the range of about 128° C. to about 135° C. (about 236° F. to about275° F.).

High density polyethylenes can be prepared by conventional methods suchas polymerizing ethylene using Ziegler catalysts at from about 1 toabout 100 atm (15 to 1500 psi) at from room temperature to about 200° F.

A preferred high density polyethylene is M3020P, formally “M2004-P”,sold by Eastman Chemical Company. M3020P is a high density polyethylenewhich has a melt index of 9.5 gms/10 min. (ASTM test method D1238), anda density of 0.944 g/cc (ASTM test method D4883). M2004-P is a highdensity polyethylene which has a melt index of 8.4 gms/10 min. (ASTMtest method D1238), and a density of 0.945 g/cc (ASTM test methodD4883).

The invention will be described further by way of the followingexamples. It should be understood, however that the invention is notlimited to the specific details set forth in the examples.

EXAMPLE 1

Sidewalls for heat insulating paper cups were fabricated with theirinside surfaces coated with Chevron PE 4517 low density polyethyleneblended with varying amounts of Eastman M2004-P high densitypolyethylene. For purposes of comparison, one sample was prepared usingan inside coating of 100% Eastman M2004-P high density polyethylene, andone sample was prepared using an inside coating of 100% Chevron PE 4517low density polyethylene. The melting point for the polyethylenecomponents present in each inside surface coating was determined usingdifferential scanning calorimetry (DSC).

Each sidewall sample was heat treated for about 1.5 minutes using aconventional production oven at 270° F. (132° C.). The samples were thenexamined to determine whether foaming occurred on the inside surface ofthe sidewall.

MELTING SAMPLE POINT (° C.) SURFACE FOAMING? 100% HDPE 131 NO 60/40%LDPE/HDPE 107/125 NO 70/30% LDPE/HDPE 107/124 NO 80/20% LDPE/HDPE107/125 NO 90/10% LDPE/HDPE 107/123 NO 100% LDPE 110 YES

EXAMPLE 2

The heat sealabilities were evaluated for 1 inch wide polyethylenecoated paper board samples prepared according to Example 1. For eachtest, the coated side of a sidewall sample was placed in contact with acontrol bottomstock coated with Chevron 4517 low density polyethylene,and a seal was effected using a Sentinel Heat Sealer Model No. 12ASL(serial no. 12-1120) available from Packaging Industries, Inc. ofHyannis, Mass. One inch sealing bars covered with Teflon tape were usedto effect the seals at a temperature of 300° F. (149° C.) for the topand bottom bars; a jaw pressure of 40 psi; and a dwell time of 0.6second.

The strengths of the heat sealed samples were then tested using an Model4202 Instron Tensile Tester available from Instron Corp. of Canton,Mass. Each sealed sample was peeled apart at a 180° angle at a crossheadspeed of 1 inch per minute. The peeled samples were then inspected todetermine whether the joint failed to exceed the strength of the board(no fiber tear) or exceeded the strength of the board (fiber tear). Afiber tear was indicated by visible paperboard fibers on both peeledsurfaces, and was indicative of an improved bond. This heat seal test isrepresentative of effective substantially leak-free cup seals.

SAMPLE FIBER TEAR BOND? 100% HDPE NO 60/40% LDPE/HDPE YES 70/30%LDPE/HDPE YES 80/20% LDPE/HDPE YES 90/10% LDPE/HDPE YES 100% LDPE YES

Although the invention has been described above in terms of preferredembodiments, it is to be understood that variations and modificationsmay be resorted to as will be apparent to those skilled in the art. Suchvariations and modifications are to be considered within the purview andscope of the claims appended hereto. For example, the specificationrefers to improved seals which can be obtained according to theinvention using materials effective to obtain such seals. Whether animproved seal exists or can be obtained can be determined by fabricatinga twelve ounce cup using a HORAUF MODEL BMP-200 machine, withtemperature controls set at between about 350° to about 460° C. and abottom expansion pressure set at about 3000 kilopascals for tworevolutions per cup. This does not mean that the invention is limited toonly twelve ounce cups or to cups made by the recited machine using therecited fabrication conditions. Furthermore, the invention is intendedto cover all paperboard containers having at least one foamedpolyethylene surface (or a portion of the surface is foamed), whether ornot they are “cups”. Of course the containers or cups may also containmore than one foamed surface as well. Other possible modifications couldinclude the use of hybrid polyethylenes such as the so-called “mediumdensity” polyethylenes (0.926 to 0.940 g/cm³ and T_(peak) of about 115°C.) and “linear low density” polyethylenes (T_(peak) of about 121 to126° C.).

What is claimed is:
 1. A heat-insulating paper container fabricated from a body member of paper having an inside surface laminate of polyethylene component effective to prevent penetration of liquid into the paper during use and an outside surface laminate of foamed low density polyethylene, said body member bonded to a bottom panel member having an upper surface and a bottom surface, wherein the inside surface laminate comprises an unfoamed modified low density polyethylene and which forms an improved seal between the bottom panel member and the body member.
 2. A heat-insulating paper container according to claim 1, wherein the inside surface laminate comprises a material that will not foam under conditions of about 240° F. to about 270° F. and a residence time of about 1.5 to about 2.5 minutes. 